Making collapsible structures



SePt 2, 1947 v. R. PANTALNE' A2,426,899'

MAKING COLLAPSIBLE STRUCTURES M Filed May 24, 1945 4 sheets-sheet 1 lNvENToR VW IQ.

AM ATTORNEY- Sept. 25 1947.v v. R. PANTALONE 2,426,899

MAKING lCOLLPSIBLE STRUCTURES Filed may 24, 1945 4 sheds-snee; 2

INVENToR VUYQM le om Je ATTORNEYv Sept 2, 1947- v. R. PANTALONE 2,426,899

MAKING COLLAPSIBLE STRUCTURES Filed May 24, 1945 4 Sheets-Sheet 4 Y le.. INVAJgNrqR ,lun- ATTDRNEY. v

Patented Sept. 2, 1947 2,426,899 MAKiNG coLLArsiLE s'rnUc'rUREs Vincent R. Pantalone, Hamden, Conn., assigner, by mesne assignments, to National Folding Box Company, Incorporated, a corporation of necticut Applicaton May 24, 1945, Serial No. 595,601

This invention relates to the art of making collapsible structures from sheets of cardboard, paperboard or other foldable sheet material.

The invention provides a method of forming a double thickness flange on a flat; blank of cardboard, paperboard or like material and has particular application to the making of tray structures for the support of merchandise between spaced upright flanges arranged on a bottom or base structure.

In the following description the invention is explained by reference to a particular application to the making of collapsible flanged trays for the support, handling, storing, packaging and shipping of stems for radio tubes. Such stems consist generally of a glass tube of considerable length with a flange shaped glass base at one end and a plurality of electrodes mounted on a glass base. The entire structure is delicate and requires very careful handling to prevent injury to the fragile and nely adjusted parts.

According to the invention a tray for the support of articles such as the aforementioned radio tube stems may be formed from a nat sheet of board by relatively few and easily performed cutting, scoring, gluing and folding operations. It is a particular feature of the invention that the trays may be pre-fabricated as flat collapsed preformed blanks requiring a minimum of space for storage and shipment and that the trays may be set up by a few simple folding operations to form on a base upstanding flanges between which radio tube stems may be securely supported so that the stems may be handled, shipped or stored without danger of injury.

The objects, features and advantages of this invention will appear more fully from the detailed description which follows accompanied by drawings showing for the purpose of illustration preferred embodiments of the invention.

The invention also consists of certain new and original features of construction and combination of parts hereinafter set forth and claimed.

Although the characteristic features of this invention which are believed to be novel will be particularly pointed out in the claims appended hereto, the invention itself, its objects and advantages, and the manner in which it may be carried out may be better understood by referring to the following description taken in connection with the accompanying drawings forming a part thereof in which,

Fig. 1 is a plan View of a cut and scored blank from which a tray embodying the invention may 7 Claims. (Cl. 93-7-1) be formed, the inside surface of the blank facing the observer;

Fig. 2 shows the blank of Fig. 1 after an initial gluing and folding operation;

Fig. 3 is a perspective view of the blank of Fig. 2;

Figs. 4, 5 and 6 Vare perspective views illustrating successive steps in the folding and setting up of a flanged tray from the blank shown in Fig. 3, Fig. 6 showing the completed tray;

Fig. 7 is a plan view of a modified form of blank;

Fig. S shows the blank of Fig. 7 after an initial gluing and folding operation;

Fig. 9 is a perspective view of the completed tray formed from the blank shown in Figs. '7 and 8;

Fig; 10 is an end View of a portion of a tray illustrating a modified manner of'folding and securing an end ilap of a tray of the general structure shown in the preceding drawings;

Fig. l1 is a perspective view illustrating the use of a plurality of trays as inserts in a carton or crate.

In the following description and in the claims various details will be identified by specific names for convenience. The names, however, are intended to be as generic in their application as the art will permit. Like reference characters refer to like parts in the several figures of the drawings.

In the drawings accompanying, and forming part of, this description, specific disclosure of the invention is made for the purpose of explanation of broader principles of the invention, but it is understood that the details may be modified in various respects without departure from the broad aspects of the invention and that the invention may be applied to other structures than the ones shown.

The blank A shown in Fig. 1 may be cut and scored in multiple from sheets or rolls of cardboard, paperboard or other suitable foldable sheet material on automatic cutting and scoring machines. The blank A is subdivided by fold lines into several panels, a bottom or main panel Il being bounded by fold lines lz and I3 at the ends and by side edges I 4 and l5 of the blank at the sides.

Top panels I6 and l1 are hingedly connected to the bottom or main panel II along the fold lines l2 and I3. Outer flange panels I8 and I9 are hingedly connected to the top panels I6 and il along fold lines 20 and 2l. Inner flange panels 22, 23 are hingedly connected to the outer flange 3 panels I8 and I9 along fold lines 24 and 25 and securing end flaps 26 and 21 are hingedly connected to the inner flange panels 22 and 23 along fold lines 28 and 29,

The inner and outer ange panels which in the finished structure support merchandise, such as radio tube stems, are provided with suitable apertures 30, 3l and 32, 33 adapted to receive and hold the merchandise therein. Preferably the configuration of the apertures is such that the apertures 30, 3| and 32, 33 of adjoining ange panels register when the panels are folded into face to face relationship to form double thickness flanges.

The fold lines I2, 20, 24 and 28 and the fold lines I3, 2 l, 25 and 29 are preferably spaced equal distances from one another resulting in `equal widths of the panels bounded by the fold lines.

The fold lines 2U and 2|, 24 and 25, 28 and 2H may be produced in various ways to obtain any desired degree of resistance to bending of the stock at the fold lines. Thus a simple impression .or scoring of the board `will preserve a certain degree of resiliency of the board, while a .partial cut through the stock will reduce its resistance to bending at the fold line. A similar weakening of the stock is obtained by an alternate ycut and crease line. The lselection of the proper kind of fold line is guided by the uses to which kthe tray is to be put. As hereinafter pointed out, Va selective preparation of the fold lines of the blank will produce structures in which the flanges will either stand upright or have a tendency of leaning resiliently to one Aside or the other .permitting parts to be held between flanges by clamping.

In the assembly of the yblank A, adhesive a is first applied to the inside surface of the securing end flaps 26 and 21 and the blank is then folded about the fold lines 2U and 2l to bring the securing end flaps 26 and 21 into adhesive engagement with the `inside surface of the bottom r 'ma-in panel II. The folded and glued blank A is shown in Figs. 2 and 3 and is in condition for a final setting-up operation. The blank A' comprises two tubular structures, one on either end, formed by the inner and outer flange panels 22, I8 and23, I9, the top panels IE, I1 and that portion of the bottom or main panel Il which lies sbetweenthe foldlines I2 and I3 and the fold lines .-28 .and 29 of the securing end flaps A2li and v21, respectively. The blank A is flat and requires a minimum of space for storage and shipping. Whenever a tray is needed without further sealing or securing opera-tions it may be set up from a blank by a few 4simple folding operations.

'In thesetting up of the blank A 'the collapsed flat tubular structures at the end of the blank are .rst erected by moving the top panels I6, I1 .and the inner flange panels 22 and 23 into Aa position substantially at right angles with respect to the lbottom panel lll as shown in Fig. 'The Atubi-,liar structures are :then collapsed by moving the top land vinn-er flange panels further tobring the top panels and l1 into surface to surface position with the -endportion of the bottom panel iI I and to :bring the louter -iiang'e panels I8 and I9 and the ,inner flange panels 22 and 23 -of .each tubular -structure into surface to surfacel position to form double thickness flanges as shown 'in Fig. 5.

lThe double thickness flanges I8, .2-2 and I9, 23 are then folded to stand substantially npr-ight on lthe bottom panel The completed tray A" is'shown in Fig. 6. Its double thickness flanges I8, 22 and I9, 23fwill remain in upright position as shown in the drawing provided the hinge lines 20, 28 and 2 I, 29 have been been weakened to substantially equal degrees. Radio tube stems 34 may then be placed in the proper apertures in the flanges which through the folding operations have been brought into registry, so that the apertures and 32 register with the apertures 3| and 33, respectively.

The blank of the tray AI may be so prepared .as to produce biased flanges which will either I lean towards or away from each other to permit clamping 4of parts therebetween. The flanges will -resiliently lean towards each other if the fold lines 29 and '21| are weakened less than the foldi'mes '23 aand .29. On the other hand, the flanges will lean away from each other if the fold lines 28 and .29 are weakened less than the fold lines 2U and 2l. This is easily understood when it is realized that panels connected at a hinge line will tend to return from a folded position to an aligned position due to the resiliency/'ofthe stock. The Vresiliency of the stock may be diminished -by partial -or intermittent cutting whereby the aforementioned biasing property of #the tray flanges is obtained.

`From an inspectionrof Figs. 3 Ito 6, particularly from `Rig, it is apparent that in lthe illustrated .embodiment a certain lfixed relationship exists between the height of the double thickness flanges, the spacing between the angeatand the Atotal length of the -tray measured between the fold-lines vIZ-.and I3. In the illustrated embodiment, the flange and top panels are of equal width permitting .the aforementioned erecting and collapsing of the tubular structures.

l-t is often desirable or necessary to have flanges of reduced height without a :decrease inthe over .all length o-f the tray, the length of the tray bei-ng determined by `the lengt-h of the articles .to .be `supported thereon, in the lpresen-t example, the length .of the radio tube stems.

Figs. '7., 8 and 9 illustrate a inodied form of blank and tray in which a reduction vof Lthe height of `the flanges is obtained without a reduction .of the .overall length -of .the tray. For reasons of convenience reference numerals have ,been `employed .in identifying parts of the blank Band of the tray .formed which dier from the reference A.numerals used in connection with the ,previously ydescribed 4embodiment by Idil. Thus ,the-bottompanel Il l --corresponds to .thebottom ,panel Il of the blank A, the .top panel IIE correspondsto .the `top panel .|.5, and.so forth.

The blank B shown V.in Fig. 7 comprises a bottom or main panel III bounded .at the sides by side edges |I4and II5 and bounded at the ends by fold lines |12 .and H3. Fold lines ||2 and II3 are interrupted by out lines l|35 and |36 leaving protruding lugs |31 .and |38 on the bottom panel III. ,The `lugs 131 and .|38 increase the .over all length of the bottom panel to the distance between the cuts |35 and |36, as will more fully appear from the following description and particularly from Fig. 9 showing `the completed tray.

The fiat -cut and scored blank B is preformed as -a collapsed flat tubular structure by folding of the blank along fold lines 12|! and IZ'I to bring the end flaps 126 and |21 finto engagement with the :bottom panel IIII. The Yend flaps '|26 and 621 are .secured to the bottom panel I-I -I by gluing, stapling or otherwise.

The at collapsed tubular blank B is ccm- -pleted into tray form by a series of folding vop elvioha The 4tubular 'structures at the ends of the bottom panel I are expanded and thereafter collapsed in a similar manner as hereinbefore described and illustrated in Figs. 4 to 6.

The iinished tray B" is shown in Fig. 9. Its over all length is the distance between the outer edges |35 and |36 of the lugs I3? and |38. 'Ihe tray accommodates structural parts of the length equal to the distance |35, |36, and may be used for shipping purposes as an insert in a carton or crate whose side walls or partitions are equal to or slightly greater than the distance between the edges |35 and |36 of the lugs.

It is obvious that the end flaps 26 and 21 or |26 and |21 may be secured to the bottom panel or in turned-under position as illustrated in Fig. 10. The drawing shows a bottom panel to which the end flap 21 of a flange assembly I9 and 23 is secured in turned-under position so as to lie underneath the top panel Il in the assembled tray.

Individual trays may be stacked and enclosed in an outer protective carton or crate 39 as indicated in Fig. l1. It is evident that in this manner a great number of fragile or delicate parts such as radio tube stems may be shipped or stored securely without danger of injury.

The invention thus provides a convenient tray or other structure which can be readily set up from a preformed flat blank Without securing operations. A particular feature of the structure is its property to move and remain in set up condition by a snap action initiated by a simple folding operation. The snap action can be controlled by weakening of the fold lines and is moreover inherent in the structure due to the particular manner in which the blank is laid out and folded. Thus, the fold lines 26 and 2| for example are more weakened than the fold lines 28 and 29, even if no cut scoring or other controlled weakening is provided for. The fold lines 26 and 2| are weakened due to the fact that the stock is folded once through an angle of 180 degrees in onev direction and thereafter through an angle of 270 degrees in the opposite direction. The first folding occurs when blank A is folded to form the structure A as shown in Fig. 3. It is noted that the preparation of the structure A as shown in Fig. 3 does not involve a weakening of the material at the fold lines 28 and 29 since the material is not yet folded at these lines. In the subsequent setting up the blank is bent 270 degrees at the fold lines 20 and 2| as shown in Fig. 5, thereby weakening the stock further at lines 20 and 2|. At the same time, the bending of the stock along the fold lines 28 and 29 never exceeds 184) degrees, thereafter reduced 'to 90 degrees in the finished tray, as shown in Fig. 6. As a result, the resiliency of the material along the fold lines 28 and 26 is greater than the resiliency along the fold lines 26 and 2|. The differential weakening thus automatically obtained by the folding operations prevents the blank from snapping back to the position of Fig. 4, whereby the structure is automatically maintained in the set up position.

Obviously the present invention is not restricted to the specific embodiments shown and described. Various modifications will be obvious to persons skilled in the art and it is clear that numerous additions, omissions, modifications and changes may be made without departure from the spirit and teaching of this invention and that the principles of the invention may be applied with equal benefit to other structures than the ones shown.

What is claimed is:

1. The method of forming a tray from a blank having a bottom pane1 and, extendingV to either end of the bottom panel and hinged thereto and to one another, a top panel, an outer flange panel, an inner flange panel, and a securing flap, the

method comprising, folding the blank to bring the iiange panels and the securing flap on either end into overlying surface to surface position with the bottom and the top panels; securing the securing flaps to said bottom panel whereby .tubular structures are formed on either end of the bottom panel; folding each tubular structure to bring the outer flange panel into surface to surface position with the respective inner flange panel and to bring the top panel into overlying surface to surface position with the bottom panel; and then erecting the flange panels into substantially upright position with respect to the bottom and top panels, whereby a collapsible tray is formed having two upstanding flanges.

2. The method of forming a collapsible tray from a flat blank having a bottom panel and, connected lthereto, at either end, a top panel hinged to the bottom panel about a first fold line, an outer ange panel hinged to the top panel about a second fold line, an inner flange panel hinged to the outer flange panel about a third fold line, and a securing ap hinged to the inner flange panel about a fourth fold line, the fold lines being spaced equal distances from one another, the method comprising, folding the blank about the second fold lines and securing the end naps to the upper surface of the bottom panel, whereby tubular structures are formed on either end of the bottom panel; erecting, and then collapsing, the tubular structures by folding the top panels about the respective rst fold lines into overlying position with the bottom panel, whereby the inner and outer flange panels are brought into surface to surface position, the outer flange panels overlying the inner flange panels; and then erecting the flange panels into substantially upright position with respect to the bottom panel, whereby double thickness flanges are formed extending parallel to either end of the bottom panel.

3. The method of forming a double thickness flange on a blank having a main panel, a topI panel connected to the main panel along a rst fold line, an outer flange panel connected to the top panel along a second fold line, an inner flange panel connected to the outer ange panel along a third fold line and a vsecuring end flap connected to the inner flange pane1 along a fourth fold line, the method comprising, folding they blank about :the second fold line and securing the end flap to the upper surface of the main panel, whereby a tubular structure is formed, erecting, and then collapsing the tubular structure by folding the top panel about the first fold line, whereby the inner and outer ange panels are brought into surface to surface position, the outer flange panel overlying the inner ange panel; and then erecting the flange panels into substantially upright position with respect to the bottom panel, whereby an upstanding double thickness flange is formed on the bottom panel.

4. The method of forming a collapsible tray from a flat blank having a bottom panel, and, extending to either end of the bottom panel, and hinged thereto and to one another along fold lines, a top panel, an inner ange panel, an outer flange panel, and a securing flap, the top panel, the inner and the outer flange panel being of substantially equal width, and the inner and outer flange panel having apertures cut therein adapted to register when the inner and outer flange panels are folded into surfaceto surface position, .the method comprising, .folding the blank to fold the. outer flange panels over the adjoining .top panels;-securing the. securing iiaps to the Vbottom panel whereby tubular structures are formed on either end of the bottom panel; erecting and theny collapsing each tubular structure to fold the toppanel over the bottom panel and to bring the ange panels into surface to surface-position the outer flange panel overlying the inner angepanelwhereby the apertures in said ange panels. are brought into .registry and then erecting the flange panels into substantially upright position with respect to the bottom panel, whereby a collapsibletray isformed having two upstanding double thicknesseflanges.

. 5. .'I-hemethod ofv fabricating a collapsible tray from. a flat blank which comprises cutting and scoring theblank near either endto form four parallel equally spacedscore lines resulting in a division. of the `blank into a bottompanel bounded byside 4edges and two rst score lines at either end,.the flrstscore lines beingintermittent so as .to providespaceol but. aligned. folding portions, theblank being cut between foldingportions to providelugs integral with. the bottom panel and projecting beyond saidrst score lines, top panels hinged to said bottom panel along said rst score lines,.outer.lange panels hinged to said top panels alongrsecond. score. lines, .inner .ange panels hinged .to said outerrflange panels along third score .lines and securing .flaps hinged to. said inner. angepanelsalong fourth score lines, said top panels, outer .andinner flange panels being of. substantially .equal width, and said flange panelsbeing cutto provide article receiving apertures adapted tobe brought into .registry by folding' ofan outer flange panel. over an adjoining inner .flange panel; folding the blank about the second .fold lines .and securing the securing end flaps tothe .upper surface of the bottom panel, whereby tubular structures are formed on either endof the bottom panel; erecting, and then collapsing, the tubular structures by folding the top panels vabout. the respective first fold lines into overlying position with the bottom. panel, whereby theinner and outerflange panels arebrought into surface to surface position, theouterflange panels overlying the inner flange panels and thearticle receiving apertures lying in registry; `and-then erecting the ange panels into substantially upright position withrespect to the bottom panel, whereby double thickness flanges are formed extending. parallel to either end of the bottom panel, the .lugs projecting beyond .saidrst fold lines increasing the overall width of `said bottom panel.

-6. .Themethod of forming a lflange structure from a.. sheet of foldable board, which comprises, weakening the vboard indi'erent degrees by impressing therein score lines of diierent magnitude toform two; spaced parallel fold-lines so. .that the board will resist `bending at one fold. lines less than at ,the other, and scoring vthe board along anl intermediate -fold line lying between said spaced iold .lines,.said1three lines defining two flange panelsof .equal ywidth hinged along said intermediate .fold line;. and then folding said two .flange panelsintoface to face position along said intermediate 'fold vline whereby said other two fold lines are rbrought into. alignment, and folding .said ange .panelsalong said other two fold lines. with respect tothe remainder-fof the board While leavingthe flangepanelsin faceto-face position, Y whereby a double. thickness flangeislformed .biasedtc lean towards oneside or the other depending on the differential weakening of. said other twofold lines.

'7. Themethod of lforming a flange structure from a. sheet `of foldable board scored to provide fourlparallel .equally spaced .fold lines thereacross, two intermediate fold lines lyingbetween two outer fold lines, Vthe saidfour foldlines defining-three panels-.of equal width, including two flange panels hingedly connected .alongone o-f. said intermediate fold lines and a. third panel hingedto one .of saidflangepanelsalong the other intermediate foldline; a main panel extending =to one sideof the said. three panels .alongone of the outercfold lines; and a securing `paneLextending to the other side. of the three panelsalong the-other outer fold line, the sheet being folded back .upon itself about the other of saidintermediate. fold lines.. the securing panel .being .secured Iface-to-face to saidmainpanel, whereby a flatcollapsed tubularV structure is formed of the sheet, the method comprising, squaring the `tubular structure by folding .saidthird` panel .into an upright .position with respect tosaidmain panel, whereby a hollow structure is formed; then recollapsing .the` tubular structure by` continuing .the folding -of .the said third panel into a position substantially.;Y degrees .with respect to its initial position, whereby thehollow structure isilattened and the flange panels arebrought face-:to-face; and :then yerecting the flange panels-into upstandingv position with` respect to the main and third-panel.

. VINCENT R. PANTALONE.

REFERENCES y CITED 'The "following :references are ofrecord ,in the le'of this patent:

,UNITED sTArrEs PATENTS 

